Disposable diaper pad



1965 P. o. PHERSON ETAL 3,211,147

DISPOSABLE DIAPER PAD Filed NOV. 1, 1962 2 Sheets-Sheet 1 PERRY O. PHERSON MENZIE GIBSON CECIL H. WATKINS MARIAN F. DUKE JAMES A.MURPHY INVENTORS ATTOR N EY 1965 P. o. PHERSON ETAL 3,211,147

DISPOSABLE DIAPER PAD Filed NOV. 1, 1962 2 Sheets-Sheet 2 FIG. 4 v /6 /7 6 /6 /0 22a PERRY 0. PHERSON MENZIE GIBSON n "1/ cacu. H. WATKINS I 1:.

MARIAN F. DUKE 5.4%,? JAMES A.MURPHY Fl 3 3 INVENTORS W BY ATTORNEY United States Patent 3,211,147 DISPOSABLE DIAPER PAD Perry 0. Pherson, West Sufiield, Conn, and Menzie Gibson and Cecil H. Watkins, Toronto, Ontario, Canada, and Marian F. Duke, New York, N.Y., and .larnes A. Murphy, Toronto, Ontario, Canada, assignors to Canadian International Paper Company, Montreal, Canada, a corporation of Canada Filed Nov. 1, 1962, Ser. No. 234,641 8 Claims. (Cl. 128284) This invention relates to a diaper pad of the disposable type. More particularly, it relates to an easily manufactured, highly absorbent diaper for use with or without a diaper holder or panties which can be disposed of in household toilets and septic tanks.

There are three primary objects of the present invention. The first is to provide infants with sanitary, efiicient, and comfortable diaper protection; the second is to provide mothers and nurses with a diaper product which they can handle cleanly and dispose of readily when it is soiled; and, the third is to provide a diaper product which is not only at least competitive as to utility and price with the standard, reusable cotton diaper, but also can be fully disposed of in the most appropriate place, i.e., the household toilet or septic tank. Other objects of the present invention will become apparent from the following disclosure and the attached drawings.

Broadly defined, the diaper of the present invention is made up of a center portion having longitudinal and lateral edges, side portions having longitudinal and lateral edges, end portions having longitudinal and lateral edges, an exterior wrapper, and exterior wrapper closure means. The center portion consists of a plurality of alternate and parallel batts or semi-columns of loose material and channel defining means. Each side portion has one of its longitudinal edges adjacent to or contiguous with a longitudinal edge of the center portion and consists of a plurality of alternate and parallel laths of loose material and channel defining means. Each end portion has one of its 1ongitudinal edges adjacent to or contiguous with a lateral edge of the center portion and lateral edges of the side portions and consists of at least one ply or layer of sheet material. The exterior wrapper is disposed, preferably overlappingly, about the center, side and end portions and the closure means are positioned outwardly of or along the other longitudinal edges of the end portions. In a preferred embodiment of the finished diaper, the side portions are partially folded upon themselves and inwardly toward the center portion (with the channel defining means therein serving as pleat edges and the laths serving as pleat folds) and are held in such position both for convenience in packaging and to provide a semi-contoured pad with which to cover the infant. Further, the closure means are provided with, at least, tearing indicia to enable the handler of the diaper, when soiled, to separate the center and side portions preparatory to or during disposal.

A clearer understanding of the product of the present invention can be gathered from a review of the preferred, in-line, continuous manner of making it and the attached drawings in which FIGURE 1 is an isometric view of the diaper of the present invention with elements thereof cut away;

FIGURE 2 is a plan view of a preferred type of closure 3,211,147 Patented Get. 12, 1965 utilized in the manufacture of the diaper of FIGURE 1;

FIGURE 3 is a sectional view of the closure means of FIGURE 2, taken along line 33;

FIGURE 4 is a sectional view of the diaper of FIG- URE 1, taken along line 44;

FIGURE 5 is an isometric view of the diaper of FIG- URE 1 when completed and just in or out of its package; and

FIGURE 6 is an isometric view of the diaper of FIG- URE 1 when ready to be put on an infant.

In a typical example of the manufacturing of the diaper of the present invention, a flat paper web 10 having width of about 32 /2 inches is continuously travelled in the horizontal plane. Preferbaly, web 11 consists of two-ply, 9% pound basis weight, 2% wet strength, crepe tissue having a stretch and about three times the strength in the length as in the width. Next, at intervals of about 16 inches along the length of web 10, paper reinforcing strips 11 are manually or mechanically laid laterally across web 11). One way of doing this is to move the reinforcing strips longitudinally above and in a direction perpendicular to the path of web 10 and to allow one edge of the strips to trial down on moving web It), so as to be drawn with the aid of such movement down upon such web. These reinforcing strips are preferably six separate, but stacked, plies or three doubledover layers of 9% pound basis weight, 2% wet strength crepe tissue paper having a stretch and they measure approximately 5 inches by 12 /2 inches.

As tissue web 10 is being reinforced, a light fluff pad web 12 is being continuously travelled in a generally horizontal plane. Fluff web is preferably about 12 /2 inches in width and consists of sulfite or sulfate wood pulp 13 which has been disintegrated or made into a loose material by means of commercially available machinery for that purpose and reformed into a pad having at least one, non-wet strength backing sheet 14 of paper tissue. Simultaneously, a second, main fluff pad. web is continuously travelled in a horizontal plane and laid down on and centrally of fluff web 12. Fluff web 15 is about 3 /2 inches wide and can have a greater thickneses or height than fluff web 12, but its composition is generally the same as that of fluff web 12 and its structure includes the same sort of loose material 16 and support sheet 17.

Once the two fluff webs 12 and 15 are brought together, they are joined together by the provision of parallel channels 18a and 18b in and over the length of fluff web 15, and that component of fluff 12 underlying fluff web 15, by standard, preferably rotary, embossing means. Such embossing divides combined webs 12 and 15 into the longitudinal batts or semi-columns 19 which will form the center portions of the eventual diapers, as well as lightly welds the two pads together.

As soon as the two pad webs 12 and 15 are thus joined together, they are ready to be laid down on and centrally of tissue web 143 having reinforcing strips 11 and the three webs are conjointly travelled to a standard folding shoe or the like which causes web 10 to envelop, preferably overlappingly, still flattened webs 12 and 15.

After the folding of web 11 the several combined longtudinally moving webs, i.e., 10, 12 and 15 are laterally embossed, centrally of reinforcing strips 11. Such embossing forms the closures of the eventual diapers and it is imporant that its character be given especial attention, because, if improperly done, can be the source of great discomfort and possible injury to the ultimate wearer of the diapers. It has been found, for instance, that when this embossing is accomplished by male and female dies, rather than two matched male embossing dies 3'17 as suggested in FIGURE 3, the result is a hardened paper strap, rather than the soft, cushioned, highly desirable band Ztl of the present invention. Such embossing can, of course, be accomplished by standard, commercially available, but preferably rotary, means and it can be accompanied by the formation of diamond cuts 2t), slits, or the like which are make to lie across the centerline of strips 11 and to run generally longitudinally with the combined Webs, so as to furnish tearing indicia or means, preferably in registry with a channel 18a, for use when disposing of the diaper.

Following the lateral embossing which provides bands 20, the combined several webs 1t 12, and t are longitudinally embossed to provide parallel channels 22a and 2212 On the side portions of the eventual diapers and to divide such portions into longitudinal laths 23 in a manner permitting a folding of such laths upon themselves (as illustrated in FIGURES 5 and 6) somewhat later in the process of manufacture. Then, glue spots 24 or the like are affixed to the cover provided by web 16, midway between bands 2t? and over the inboard laths 23; the side portions of the combined assembly are longitudinally pleated along the foldlines provided by channels 22a and 2211, so as to become partially fastened in place by glue spots 24; a peg or spot embossing 25 is provided on the outboard laths 23 as they overlie the inboard laths, in registry with glue spots 24, to complete the fastening; and, to end the process, the diapers are formed, and their closures are perfected, by laterally severing bands 20 along their centerlines, so that one set of reinforcing strips 11 provides the end portions of two adjacent diapers. Again, the nature and means of this severing is most important to the comfort and safety of the diaper wearer. For, it has been found that a sharp knife cut produces a hard edge on the band which is not permissible against, for instance, an infants skin, while an extension of the pressure sealing shown in copending Serial No. 86,734, (now abandoned but c.f. Canadian Patent No. 660,343 issued March 26, 1963, to Canadian International Paper Company) wherein papers fibers are to an extent welded together, yields an acceptable product. Such a severing can be achieved by over-embossing along a line or using a shear cut to furnish diaper ends 26 without an abrading or chafing edge. Use of a band saw is also advantageous.

The outstanding merits of the product in accordance with the present invention are manifest. No toilet or septic tank clogging materials are employed; the product can be entirely composed of paper, or, more broadly, wood pulp derivatives. Again, the channels in the diaper which initially promote a better distribution of the discharged body fiuids of the wearer and, therefore, a better absorption of such fluids better conture the garment to the wearer and then aid in its disposal by furnishing tearing lines. The diaper closures too present no disposal problem, since they utilize no adhesives or non-paper materials. In addition, they obviate the inclusion of possible irritating compositions and avoid discomforting structures and they provide sections of the diaper strong enough to permit the use of safety pins therethrough to hold the diapers without, if necessary, the use of rubber panties or the like.

What is claimed is:

1. A diaper comprising:

a generally rectangular pad formed of an absorbent wood pulp,

said pad having pairs of opposing side and end edges and including a central portion extending from end to end of said diaper, said central portion being of substantially greater thickness than flanking outer portions, and wherein said flanking outer portions are thin and of appreciable width,

an envelope of wet strength, creped tissue enclosing said pad, said tissue having a strength in one direction greater than its strength in a direction transverse to said one direction and being arranged relative to said pad such that the line of strength of the tissue extends transversely of the end edges of the pad; and,

at least one reinforcing strip of wet strength, creped tissue generally transversely of the side edges of the pad adjacent each of the end edges thereof to define a reinforcing band capable of encircling a diaper wearers Waist,

said band being effective to increase the strength of the diaper adjacent its end edges,

said strip having a width measured longitudinally of the pad substantially less than the length of the pad, and,

the fibers in said end area being interconnected so as to maintain said strips in a predetermined position relative to said pad.

2. A diaper in accordance with claim 1, wherein said pad is formed of alternate and parallel batts of wood pulp fluff and first channel defining means and an underlying plurality of alternate and parallel first laths of wood pulp fluff and second channel defining means in registration with the first channel defining means.

3. The diaper of claim 1 wherein fibers of the said transversely arranged strips are interconnected with the fibers of said pad by embossing so as to provide a high strength area adjacent the ends of the pad adapted to receive and hold fastening means such as a safety pin.

4. The diaper of claim 1 wherein the edges of said envelope adjacent each of the said end edges of said pad are provided with short cut-lines extending transversely of the end edges to facilitate the separation of the diaper into segments for disposal.

5. A diaper comprising:

a generally rectangular pad formed of an absorbent wood pulp,

said pad having pairs of opposing side and end edges;

an envelope formed of wet strength, creped tissue enclosing said pad,

said tissue having a strength in one direction greater than its strength in a direction transverse to said one direction and being arranged relative to said pad so that the line of strength of the tissue extends transversely of the end edges of the pad; and,

the portions of said enclosed pad located adjacent each of the side edges thereof being folded inwardly and then back upon themselves to form pleats each having two folds,

said pleats being substantially narrower in width than the pad and being spaced apart to provide a relatively large absorptive area in the central portion of the pad intermediate the pleats, a fold of each of the pleats being secured to the unpleated portion of the pad,

the portions of the pad folded to form the pleats being of lesser thickness than the central unfolded portion of the pad, said pleats being adapted to provide edge seals in the area in which the diaper surrounds the diaper wearers legs.

6. A diaper in accordance with claim 5 wherein at least one reinforcing strip of wet strength creped tissue is disposed within the envelope generally transversely of the side edges of the pad adjacent each of the end edges thereof to define a reinforcing band capable of encircling a diaper wearers waist.

'7. A diaper in accordance with claim 5 wherein said pad is formed of alternate and parallel batts of wood pulp fluff and first channel defining means and an underlying plurality of alternate and parallel first laths of References Cited by the Examiner FOREIGN PATENTS 2,788,003 4/57 Morin 128284 Dexter l28-284 Lomberg-Holrn 128284 Hansen 128-284 Goldstone 1S6--209 Harmon 156-209 Gobbo et a1. 128287 RICHARD A. GAUDET, Primary Examiner. 1O JORDAN FRANKLIN, Examiner. 

1. A DIAPER COMPRISING: A GENERALLY RECTANGULAR PAD FORMED OF AN ABSORBENT WOOD PULP, SAID PAD HAVING PAIRS OF OPPOSING SIDE AND END EDGES AND INCLUDING A CENTRAL PORTION EXTENDING FROM END TO END OF SAID DIAPER, SAID CENTRAL PORTION BEING OF SUBSTANTIALLY GREATER THICKNESS THAN FLANKING OUTER PORTIONS, AND WHEREIN SAID FLANKING OUTER PORTIONS ARE THIN AND OF APPRECIABLE WIDTH, AN ENVELOPE OF WET STRENGTH, CREPED TISSUE ENCLOSING SAID PAD, SAID TISSUE HAVING A STRENGTH IN ONE DIRECTION GREATER THAN ITS STRENGTH IN A DIRECTION TRANSVERSE TO SAID ONE DIRECTION AND BEING ARRANGED RELATIVE TO SAID PAD SUCH THAT THE LINE OF STRENGTH OF THE TISSUE EXTENDS TRANSVERSELY OF THE END EDGES OF THE PAD; AND, AT LEAST ONE REINFORCING STRIP OF WET STRENGTH, CREPED TISSUE GENERALLY TRANSVERSELY OF THE SIDE EDGES OF THE PAD ADJACENT EACH OF THE END EDGES THEREOF TO DEFINE A REINFORCING BAND CAPABLE OF ENCIRCLING A DIAPER WEARER''S WAIST, SAID BAND BEING EFFECTIVE TO INCREASE THE STRENGTH OF THE DIAPER ADJACENT ITS END EDGES, SAID STRIP HAVING A WIDTH MEASURED LONGITUDINALLY OF THE PAD SUBSTANTIALLY LESS THAN THE LENGTH OF THE PAD, AND, THE FIBERS IN SAID END AREA BEING INTERCONNECTED SO AS TO MAINTAIN SAID STRIPS IN A PREDETERMINED POSITION RELATIVE TO SAID PAD. 